Sun tracking solar power system hardware and method of assembly

ABSTRACT

A solar energy collection system can include improved mounting hardware for reducing hardware costs and labor required for assembly. For example, mounting hardware can include surfaces for supporting part or all of the weight of a solar module as it is brought into contact with mounting hardware and then moved into a final engaged position. In some systems, a torque tube can include saddle mount assemblies that allow a solar module to be partially engaged and a registered with the saddle mount while being pivoted into a final locked engagement. Some systems can include arrangements sufficient to support the full weight of a solar module in a disengaged position, and as it is moved into a final engaged position. Some systems can include a configuration of apertures and interference or snap-fit features for providing tool-less connections, thereby simplifying the assembly process.

TECHNICAL FIELD

The present disclosure generally relates to components for solar powersystems, and more specifically, components for connecting and mountingsolar power components such as for sun tracking systems.

BACKGROUND

Some known sun-tracking photovoltaic solar power systems, such asutility-scale, photovoltaic installations, are designed to pivot a largenumber of solar modules so as to track the movement of the sun using thefewest possible number of drive motors. For example, some known systemsinclude parallel rows of photovoltaic modules supported on torque tubes.The torque tubes can comprise a number of long, round shafts connectedtogether in an end to end fashion, typically fabricated out of metal.

As such, the torque tubes and some of the associated hardware canpresent a substantial cost of a sun tracking solar power system. Thus,reducing the material, manufacturing costs and/or labor required forassembly of such components can present significant reductions in thecost of financing the initial construction of such a system. Reducingthe construction cost of such systems can significantly impact theability to attain financing for such systems, the servicing of which issufficiently low to allow such a system to sell electricity, forexample, to a regional grid power distribution system, at a rate that issufficiently high to cover the debt servicing for such initialconstruction.

BRIEF SUMMARY

An aspect disclosed herein includes the realization that conventionalhardware for mounting solar modules to sun tracking systems can bemodified to provide simplified and faster procedures for making theappropriate connections, thereby reducing the labor costs associatedwith such mounting procedures. For example, some embodiments disclosedherein include the realization that hardware can be provided forconnecting solar modules to torque tubes with tool-less connections,such as snap fit or other interference type connection mechanisms.

For example, in some embodiments, a solar energy collection system caninclude first and second solar modules, each comprising a solarcollection member including an upper surface configured to receivesunlight for conversion into electrical energy and a lower surfaceopposite the upper surface, each of the first and second modules alsocomprising a support frame connected to the lower surface of the solarcollection member. A torque member having a longitudinal axis supportedabove the ground so as to be pivotable through a range of pivot motioncan also be included. A plurality of solar module retention members canbe fixed to the torque member and comprise a tool-less connection, thetool-less connection having sufficient strength to remain engaged withthe support frames of the first and second modules as the torque memberis tilted through its sun tracking range of motion.

In some embodiments, a solar energy collection system can comprise firstand second solar modules each comprising a solar collection memberincluding an upper surface configured to receive sunlight for conversioninto electrical energy and a lower surface opposite the upper surface.The first solar module can also comprise a supporting frame supportingthe solar collection module. The first solar module can have a lengthextending along a longitudinal direction of the solar collection member.The frame can comprise a first side portion connected to the lowersurface of the solar collection member on a first side and approximatelyparallel to the longitudinal axis of the solar collection member andincluding a first lateral surface extending approximately perpendicularto the upper surface and a first aperture disposed in the first lateralsurface. A second side portion of the frame can be connected to thelower surface of the solar collection member and extending along asecond side of the longitudinal axis of the solar collection memberopposite the first side. A torque member can be supported above theground surface so as to pivot about a first pivot axis which extendsgenerally along a longitudinal direction of the torque member. A firstsolar module retention member can be fixed to the torque member at afirst location. The first solar module retention member can include afirst projection extending approximately parallel to the first pivotaxis and into the first aperture. A second solar module retention membercan be fixed to the torque member at a second location spaced from thefirst location by a distance approximately equal to a distance betweenthe first and second side portions of the frame. The second solar moduleretention member can include a tool-less fastener engaged with thesecond side portion. The first projection and the first aperture can besized so as to allow the first solar module to be pivoted about thefirst aperture through a range of pivotal motion of at least about tendegrees between a first tilted position in which the first projection isengaged with the first aperture and the second side portion iscompletely disengaged from the tool-less fastener in a second positionin which the first projection is engaged with the first aperture and thesecond side portion is engaged with the tool-less fastener.

In some embodiments a solar energy collection system can comprise afirst solar module comprising a solar collection member including anupper surface configured to receive sunlight for conversion intoelectrical energy and a lower surface opposite the upper surface. Thefirst solar module can also comprise a support frame supporting thesolar collection module, the first solar module having a lengthextending along a longitudinal axis of the solar collection member. Theframe can comprise a first side portion connected to the lower surfaceof the solar collection member on a first side of the longitudinal axis.A second side portion of the frame can be connected to the lower surfaceof the solar collection member and extending along a second side of thelongitudinal axis opposite the first side. A torque member can besupported above the ground surface so as to pivot about a first pivotaxis which extends generally along a longitudinal direction of thetorque member. A first solar module retention member can be fixed to thetorque member at a first location. The first solar module retentionmember can include first and second flat portions disposed on oppositesides of the pivot axis. A second solar module retention member can befixed to the torque member at a second location spaced from the firstlocation by a distance approximately equal to a distance between thefirst and second side portions. The second solar module retention membercomprising third and fourth can comprise third and fourth flat portionsdisposed on opposite sides of the pivot axis.

At least a first connector portion disposed adjacent to the first flatportion can be included, wherein the first, second, third, and fourthflat portions are arranged so as to stably support the first solarmodule with the first side portion resting on the first and second flatportions and the second side portion resting on the third and fourthflat portions. The first, second, third, and fourth flat portions beingsized to stably support the first and second side portions with thefirst solar module in a first position in which this first side portionis completely disengaged from the first connector portion and to stablysupport the first and second side portions as the first solar module ispushed in a direction so as to cause the first and second side portionsto slide across the first, second, third, and fourth flat portions intoa second position in which the first side portion is engaged with thefirst connector portion.

In some embodiments, a solar energy collection system can comprise atleast a first solar module comprising a solar collection memberincluding an upper surface configured to receive sunlight for conversioninto electrical energy and a lower surface opposite the upper surface.The first solar module can also comprise a support frame supporting thesolar collection module. A torque member can be supported above a groundsurface so as to pivot about a first pivot axis which extends generallyalong a longitudinal direction of the torque member. A first solarretention member can be fixed to the torque member at a first locationand contacting the support frame so as to support the first solarmodule. The first solar module retention member comprising a channelmember having a substantially uniform channel cross section along asubstantial portion of its length and extending along a generallyW-shape and comprising first and second outer arm portions connected toa central curved portion, the central curved portion being fixed to thetorque member.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the subject matter may be derived byreferring to the detailed description and claims when considered inconjunction with the following figures, wherein like reference numbersrefer to similar elements throughout the figures.

FIG. 1 is a schematic diagram of a prior art sun tracking photovoltaicsystem, with which the present embodiments can be used.

FIG. 2 is a schematic diagram of an electrical system for thephotovoltaic system of FIG. 1.

FIG. 3 is a perspective view of the solar collection system of FIG. 1,illustrating a plurality of piles mounted to the ground and supporting aplurality of torque tubes with a sun-tracking drive in accordance withan embodiment;

FIG. 4 is a perspective view of an embodiment of a solar moduleretention member arrangement;

FIG. 5 is an enlarged perspective view of one end of another embodimentof the solar module retention member of FIG. 4;

FIG. 6 is a side elevational schematic view of a step of a method thatcan be used for mounting a solar module to the retention members ofFIGS. 4 and 5;

FIG. 7 is a side elevational view of another step of a method that canbe used to attach a solar module to the solar module retention membersof FIGS. 4 and 5;

FIG. 8 is a perspective view of another embodiment of a solar memberretention member;

FIG. 9 is another perspective view of the solar module retention memberof FIG. 8 engaged with a frame member of a solar module;

FIG. 10 is a perspective and partial sectional view of the solar moduleretention member of FIG. 9;

FIG. 11 is perspective view of a plurality of solar modules attachedwith a plurality of the solar module retention members of FIG. 9;

FIG. 12 is a perspective view of another embodiment of a solar moduleretention member;

FIG. 13 is a perspective view of the solar module retention member ofFIG. 12 supporting a frame member of a solar module;

FIG. 14 is a side elevational schematic view of two of the solar moduleretention members of FIG. 12 supporting two frame members of a solarmodule in a first position;

FIG. 15 is a side elevational schematic view of the arrangement of FIG.14 with the solar module slid toward the right so as engage the framemembers of the solar module with the solar module retention member;

FIG. 16 is a an enlarged perspective view of one end of the solar moduleretention member of FIG. 12 and a partial sectional view of the framemember engaged therewith.

DETAILED DESCRIPTION

The following detailed description is merely illustrative in nature andis not intended to limit the embodiments of the subject matter or theapplication and uses of such embodiments. As used herein, the word“exemplary” means “serving as an example, instance, or illustration.”Any implementation described herein as exemplary is not necessarily tobe construed as preferred or advantageous over other implementations.Furthermore, there is no intention to be bound by any expressed orimplied theory presented in the proceeding technical field, background,brief summary, or the following detailed description.

Certain terminology may be used in the following description for thepurpose of reference only, and thus are not intended to be limiting. Forexample, terms such as “upper”, “lower”, “above”, and “below” refer todirections in the drawings to which reference is made. Terms such as“front”, “back”, “rear”, “side”, “axial”, and “lateral” describe theorientation and/or location of portions of the component within aconsistent but arbitrary frame of reference which is made clear byreference to the text and the associated drawings describing thecomponent under discussion. Such terminology may include the wordsspecifically mentioned above, derivatives thereof, and words of similarimport. Similarly, the terms “first”, “second”, and other such numericalterms referring to structures do not imply a sequence or order unlessclearly indicated by the context.

“Coupled”—The following description refers to elements or nodes orfeatures being “coupled” together. As used herein, unless expresslystated otherwise, “coupled” means that one element/node/feature isdirectly or indirectly joined to (or directly or indirectly communicateswith) another element/node/feature, and not necessarily mechanically.

“Tool-less connection”—The following description refers to devices orfeatures being connected with “tool-less connections”. As used herein,unless expressly stated otherwise, “tool-less connection” means that oneelement/node/feature is directly or indirectly joined to (or directly orindirectly communicates with) another element/node/feature with amechanism that can be operated by a human without any tools or otherseparate parts to achieve a joined state and optionally to bedisconnected from the joined state.

“Locating connector”—The following description refers to devices orfeatures being connected with a “locating connector”. As used herein,unless expressly stated otherwise, “locating connector” means that oneelement/node/feature is directly or indirectly joined to (or directly orindirectly communicates with) another element/node/feature with amechanism that connects and also provides a locating function, such asfor example but without limitation, alignment of elements/nodes/featuresor enhancing contact between two elements/nodes/features.

The embodiments disclosed herein are described in the context ofsun-tracking photovoltaic arrays and modules. However, these embodimentscan be used in other contexts as well, such as non-sun-tracking solarsystems, as well as concentrated photovoltaic solar systems andconcentrated thermal solar systems, etc.

In the description of FIGS. 1-3 set forth below, an example of a priorart solar energy collection system 10 is described in the context ofbeing formed by a plurality of solar collector devices, supported bytorque tubes so as to be pivotally adjustable for sun-tracking purposes.Embodiments described below with reference to FIGS. 4-17, can be usedwith the solar collection system 10 illustrated in FIGS. 1-3, as well asthe variations and equivalents thereof, including but withoutlimitation, concentrated thermal solar systems.

FIG. 1 illustrates a prior art solar collection system 10, which can beconsidered an electricity farm. The solar collection system 10 includesa solar collector array 11 which includes a plurality of solarcollection modules 12. Each of the solar collection modules 12 caninclude one or a plurality of solar collecting devices 14 supported by adrive shaft or torque tube 16. Each of the torque tubes 16 are supportedabove the ground by a support assembly 18, and can be bolted to, ormechanically linked to each other, by a torque transmission member or“coupling flange” located on at least one end of the torque tube 16.

With continued reference to FIG. 1, the system 10 can also include atracking drive 30 connected to the torque tube 16 and configured topivot the torque tube 16 so as to cause the collector devices 14 totrack the movement of the sun. In the illustrated embodiment, the torquetubes 16 are arranged generally horizontally and the modules 12 can beconnected to each other and the torque tubes 16, as more fully describedin U.S. patent application Ser. No. 13/176,276, filed Jul. 5, 2011, theentire contents of which is hereby expressly incorporated by reference.However, embodiments disclosed herein can be used in the context ofother types of arrangements. For example, the system 10 can include aplurality of modules 12 that are arranged such that the torque tubes 16are inclined relative to horizontal, wherein the torque tubes 16 are notconnected in an end to end fashion, such as the arrangement illustratedand disclosed in U.S. Patent Publication No. 2008/0245360. The entirecontents of the 2008/0245360 patent publication, as well as the entirecontents of the U.S. patent application Ser. No. 13/631782 are herebyexpressly incorporated by reference. Further, the embodiments disclosedherein can be used in conjunction with the systems that provide forcontrolled tilting about two axes, although not illustrated herein.

The solar collection devices 14 can be in the form of photovoltaicmodules, thermal solar collection devices, concentrated photovoltaicdevices, or concentrated thermal solar collection devices. In theillustrated embodiment, the solar collection devices 14 are in the formof non-concentrated, photovoltaic (PV) modules. The photovoltaic modules14 can include one or more photovoltaic cells, encased in a frameassembly including an optically transparent upper cover and a peripheralframe. The design and structure of such photovoltaic modules are wellknown in the art are thus are not described in further detail.

With reference to FIG. 2, solar collection system 10 can further includean electrical system 40 connected to the array 11. For example, theelectrical system 40 can include the array 11 as a power sourceconnected to a remote connection device 42 with power lines 44. Theelectrical system 40 can also include a utility power source, a meter,an electrical panel with a main disconnect, a junction, electricalloads, and/or an inverter with the utility power source monitor. Theelectrical system 40 can be configured and can operate in accordancewith the descriptions set forth in U.S. Patent Publication No.2010/0071744, the entire contents of which is hereby expresslyincorporated by reference. Other electrical systems can also be used.

FIG. 3 illustrates the array 11 with all but one of the solar collectiondevices 14 removed. As shown in FIG. 3, each of the support assemblies18 includes the bearing 20 supported at the upper end of a pile 22. Thetorque tube 16 can be of any length and can be formed in one or morepieces. The spacing of the piles 22, relative to one another, can bedetermined based on the desired limits on deflection of the torque tubes16 between the support structures 18, wind loads, and other factors.

The tilt drive 30 can include a drive strut 32 coupled with the torquetube 16 in a way that pivots the torque tube 16 as the drive strut 32 ismoved axially along its length. The drive strut 32 can be connected withthe torque tube 16 with torque arm assemblies 34. In the illustratedembodiment, the torque arm assemblies 34 disposed at an end of each ofthe torque tube 16.

Also illustrated in FIG. 3 is a solar module retention memberarrangement 100 including one or more solar module retention membersfixed to a torque tube 16, which are generally referred to as “saddlemembers” in the art. Detailed descriptions of the various embodiments ofthe solar module retention arrangements 100, 100A, 100B are describedbelow with reference to FIGS. 4-16.

The torque tube 16 can have a solid or cylindrical body, extending alonga longitudinal axis L. The cylindrical body can have any cross-sectionalshape, including but without limitation, round, square, triangular,rectangular, polygonal, or other shapes. Thus, as used herein, the term“cylindrical” is intended to mean “a surface or solid bounded by twoparallel or skewed planes and generated by a straight line movingparallel to the given planes and tracing a closed shape with any numberof curved and/or straight segments, bounded by the planes and lying in aplane perpendicular or oblique to the given planes.”

An aspect of at least one of the embodiments disclosed herein includesthe realization that certain components of solar power systems, such asthose components used to attach solar collection devices to pivotingstructural members such as torque tubes, can be made at lower costs thanknown designs. For example, solar module retention members, also knownas “saddle mounts” typically include a curved central portion and flatdistal ends on either side of the curved central portion. The curvedcentral portion is shaped so as to correspond to an outer surface of atorque tube for facilitating secure connection thereto. The flatportions at the opposite ends of the saddle are used for supporting thesolar collection devices.

The relatively complex shape of saddle mounts resulted in some priordesigns which include side walls having a generally straight upper edgeand a lower edge that extends through a wave-like configuration, thusresulting in a member having a non-uniform cross-section along itslength.

With reference to FIG. 4, an improved solar member retention assembly100 can include one or more saddle members 102, 104. At least one of thesaddle members 102, 104 can have a generally uniform cross section alongtheir length which extends in a direction generally transverse to theaxis L of the torque tube 16, and includes flat portions at oppositedistal ends and a curved central portion.

For example, the saddle members 102, 104 can include first distal ends106, 108 respectively and second distal ends 110, 112, respectively. Thefirst and second ends 106, 110 of the saddle member 102 can be generallycoplanar with each other. Additionally, optionally, the first and secondends 108, 112 of the saddle member 104 can also be coplanar with eachother and coplanar with the first and second ends 106, 110 of the saddlemember 102. Other configurations can also be used.

The saddle members 102, 104 also include a curved central portion 114,116. The curved central portions 114, 116 include a convexly curvedcentral shape that is complimentary to an outer surface of the torquetube 16. As such, the saddle mounts 102, 104 generate a curved contactarea 118, 120 which facilitates connection to the torque tube 16, forexample, but without limitation, by welding.

As noted above, the saddle members 102, 104 can include a generallyuniform cross sectional shape along their length, between their firstends 106, 108 and their second ends 110, 112. For example, a crosssection of the saddle members 102, 104 at any position between the firstends 106, 108 and the second ends 110, 112 is generally channel-shaped.As such, each of the saddle mounts 102, 104 have a generally W-shapedconfiguration and a generally uniform cross section between the firstends 106, 108 and the second ends 110, 112. Such a shape can beconveniently manufactured by a stamping process. For example each of thesaddle mounts 102, 104 can be formed initially with a flat piece ofsheet metal or a channel member, and then stamped into the illustratedshape.

Although described herein as having a generally uniform cross section,the saddle mounts 102, 104 also include additional connection features,described in greater below, at the first ends 106, 108 and the secondends 110, 112. Thus the cross section of the saddle mounts 102, 104 arenot entirely uniform at the distal ends.

For example, the saddle mount 102 includes a first side wall 122 and asecond side wall 124. The side walls 122, 124 are connected by a centralweb portion 126. The side walls 122, 124, and the central web portion126 extend parallel to each other. Additionally, the distal portions ofthe central web portion 126 form the flat first and second end portions106, 110. Similarly, the saddle mount 104 includes side walls 128, 130and a central web portion 132.

In the illustrated embodiment, the combination of the saddle mounts 102,104 define a solar collector retention assembly 100, which cooperatewith each other to securely retain a solar collection device to thetorque tube 16.

In the illustrated embodiment, the saddle mount 102 can include aconnector member 134 configured to engage and thereby retain a solarmodule to the saddle mount 102. For example, in some embodiments, theconnector 134 can be configured to provide a snap fit with a solarmodule. For example, the connector member 134 can include at least onedeflectable projection 136 configured to be biased so as to snap fitwith a feature on a solar module, described in greater detail below.Optionally, the connector member 134 can include a second deflectableprojection 138 also biased so as to provide a snap fit engagement with afeature on a solar module.

The connector member 134, optionally, can include first and second sidewalls 140, 142 and a central web portion 144 connecting the side walls140, 142. The size of the web portion 144 and side walls 140, 142 can beconfigured to fit over at least a portion of the flat portion 106 of thefirst end of the saddle mount 102. For example, the side walls 140, 142can be spaced such that the connector member 134 can fit around theportions of the side walls 122, 124 adjacent the first end 106 of thesaddle mount 102. Optionally, the connector member 134 can include a tab146 configured to fit over an upper side of the flat end 106 with thecentral web portion 144 extending below the flat portion 106.Optionally, a second connector member (not shown) the same or similar tothe connector member 134 can be provided for the second end 110 of thesaddle mount 102.

FIG. 5 illustrates the connector member 134 engaged with the first end106 of the saddle mount 102. Additionally, FIG. 5 illustrates thedeflectable projection 136 extending into an aperture 150 of a framemember 152 of a solar module. The frame member 152 can be mounted onlyto a bottom surface of a solar energy collection device, such as a“laminate.” Alternatively, the frame member 152 could be the type offrame member that extends along a portion of a periphery of a laminateof a solar module.

Optionally, the connector member 134 can be made integrally ormonolithically with the saddle member 102. In some embodiments, theconnector member 134 can be made from spring steel, which furtherfacilitates the deflectable nature of the deflectable portions 136, 138,for example, deflecting outwardly as a portion of a solar module passesbetween he projections 136, 138 and the return of the deflectableprojections 136, 138 toward their biased position so as to retain asolar module in a desired location, described in greater detail below.

With continued reference to FIG. 4, the saddle member 104 can includeone or more projections. For example, the saddle member 104 can includea projection 160 disposed at the first end 108 of the saddle member 104.The projection 160 can be configured to engage a feature on a frame of asolar module. Further, the projection 160 can be a “locating connector”,for example, it can be configured to provide for a positive locatingfunction of a solar module while allowing a solar module to be pivotedrelative to the saddle mount 104 and/or the saddle mount 102. In someembodiments, the projection 160 is made from a bent piece of the saddlemount 104. For example, where the saddle mount 104 is made from stampedsheet material, a portion of the sheet material can be bent transverselyrelative to the side wall 130 so as to extend inwardly toward thecentral web portion. Optionally, the saddle mount 104 can include asecond projection 162 disposed at the second end 112 of the saddle mount104. Similarly, the projection 162 can be configured to extend into afeature, such as an aperture, on a frame of a solar module. Further, theprojection 162 can be configured to allow the solar module to be tiltedrelative to the saddle mounts 104 and/or 102 while remaining engaged andthereby positively located by the projection 162.

With reference to FIGS. 6 and 7, the saddle mounts 102, 104 can beconfigured to engage and retain a solar module 170. The solar module 170can have any typical configuration. For example, the solar module 170can include a laminate 172 which can include one or more “solar cells,”having any configuration, and encapsulated within an “encapsulant.” Thesolar cells within the laminate 172 face upwardly (as oriented in FIGS.6 and 7) so as to be exposed to sunlight for a conversion of sunlightinto electrical energy. In some embodiments, the solar module 170 caninclude one or more electrical components 174 such as a junction box,inverter, or other devices. In the illustrated embodiments, the laminateextends in a longitudinal direction A (FIGS. 3, 6, and 7). Otherconfigurations can also be used. Such designs are well known in the artand are not described in greater detail below.

Additionally, the solar module can have one or more frame members, suchas frame member 152 noted above and frame member 154 (FIG. 6). In theconfiguration illustrated in FIGS. 6 and 7, the two frame members 152,154 are bonded directly to a lower side of the laminate 172.

In other embodiments (not shown), the module 170 can include a pluralityof frame members extending along an outer periphery of the laminate 172.Those of ordinary skill in the art can understand how to apply theteachings and disclosures set forth herein to modules having peripheralframes.

In some embodiments, the frame members 152, 154 can extend generallyparallel to the longitudinal axis A of the laminate 172. Additionally,the frame members 152, 154 can be positioned generally symmetricallyrelative to the longitudinal axis A, thereby providing the module 170with a balanced arrangement of the frame members 152, 154.

In some embodiments, the frame members 152, 154 can each include one ormore apertures, such as the aperture 150 described above with referenceto FIG. 5. For example, the frame members 152 can include four apertures150 disposed on opposite lateral sides of each frame member 152 so as tobe generally aligned with the deflectable projections 136, 138 disposedat each of the longitudinal ends 106, 110 of the saddle member 102.

Similarly, the frame member 154 can include one or more apertures, suchas the aperture 150 on the frame member 152, in a position so as to bealigned with the projections 160, 162 on the saddle member 104 (FIG. 4).Optionally, the frame members 152, 154 can each have four of the samesized apertures in the same locations. Such a configuration of the framemembers 152, 154 provide additional cost savings in that the framemembers 152, 154 can be identical to each other, and thus remove theneed for creating two different frame members for each module 170.However, other configurations can also be used.

In some embodiments, the apertures 150 on the frame member 154 and theprojections 160, 162 can be configured so as to capture the frame member154 so as to register the position of the module relative to the torquetube 16 in a direction generally parallel to the axis A of the solarmodule 170, with the flat surfaces at the ends 108, 112 of the saddlemember 104, providing support to the frame member 154 in the verticaldirection and the side wall 130 of the saddle member 104 preventingfurther movement of the module 170, relative to the torque tube 16,towards the right-hand side of FIG. 6.

Additionally, the aperture 150 on the frame members 154 and theprojections 160, 162 can be sized and configured to allow the module 170to be tilted through a range of motion, represented by angle 180 of FIG.6, between a horizontal orientation (illustrated in phantom andcorresponding to the position illustrated in FIG. 7) and a tilted-upposition with the apertures in the frame member 154 remaining engagedwith the projections 160, 162. The projections 160, 162 and theapertures 150 in the frame member 154 can be sized so as to remainengaged when pivoted through an angle 180 between about 5 and 20degrees.

As such, when an assembler is attaching the module 170 to the torquetube 16, the assembler can first engage the frame member 154 with thesaddle member 104 by aligning the apertures 150 of the frame member 154with the projections 160, 162, with the module 170 tilted in anup-tilted position, then tilt the module 170 downwardly so as to engagethe frame member 152 with the saddle member 102.

This configuration can significantly simplify installation processes andreduce the number of people required for engaging a solar module 170with a torque tube 16.

Optionally, as noted above, the solar module retention assembly 100 caninclude a tool-less connection. Thus, with continued reference to FIGS.5, 6 and 7, as the frame member 152 is moved into engagement with thesaddle member 102, the deflectable projections 136, 138 can be firstdeflected outwardly as a lower surface of the frame member 152 contactsthe sloped upper faces of the deflectable projections 136, 138, thensnap inwardly such that the deflectable projections 136, 138 snap intothe apertures 150 on the frame member 152.

The connector 134, including the portions of the connector 134 formingthe deflectable projections 136, 138, can be made from any material.Further benefits can be achieved by forming the connector 134 fromspring steel. As such, the thickness and shape of the connector member134, and in particular the portions forming the deflectable projections136, 138, can be designed to provide the desired retaining performancefor retaining the frame member 152 within the saddle mount 102.

For example, engaged in the position illustrated in FIG. 7, it isdesirable that the projections 160, 162 on the saddle member 104 and thedeflectable projections 136, 138 of the saddle member 102 can cooperateto retain the solar module 170 in the engaged position illustrated inFIG. 7 as the torque tube 16 is rotated through its sun-tracking rangeof motion, which can be as much as about 45 degrees from horizontal.Further, optionally, the connector members 134 and projections 160, 162can be configured to retain the solar module 170 in the engaged positionillustrated in FIG. 7 with the torque tube 16 completely inverted, suchthat the entire weight of the module 170 is supported by the projections160, 162 and the connector members 134, and more specifically, thedeflectable projections 136, 138. Further, the projections 160, 162 andthe connector members 134 can be configured to retain the solar modulein the engaged position illustrated in FIG. 7 under any design loadparameters, such as maximum wind forces that may act upon the modules170. Thus, in some designs, the projections 160, 162 and the connectormembers 134 can be configured to withstand upward forces of about atleast 200 pounds. In some sites, higher wind loads might present a needfor the connections to be configured to loads of up to 1500 lbs. Thoseof ordinary skill in the art know how to size the materials of thevarious components described above to withstand such loads.Additionally, any of the embodiments disclosed herein can also includeother types of fasteners to supplement the holding effect of thetool-less connections, for example, but without limitation, threadedfasteners, rivets, welds, etc.

With reference to FIGS. 8-11, a further embodiment of the solar moduleretention assembly 100 is illustrated therein and identified generallyby the reference numeral 100A. Components of the solar module retentionmember 100A that are the same or similar to the solar modular retentionassembly 100 are identified with the same reference numerals, exceptthat a letter “A” has been added thereto.

The solar module retention assembly 100A can include one or a pluralityof saddle members 102A, which are similar to the saddle member 102illustrated in FIG. 4. Primarily, the difference between the saddlemember 102 illustrated in FIG. 4 and the saddle member 102A illustratedin FIG. 8 is features disposed at the distal ends 106, 110.

As shown in FIG. 8, the side walls 122, 124 include apertures 200 and202, respectively. With reference to FIGS. 9-11, each of the solarmodules 170A can include frame members 152A, 154A, each of which caninclude deflectable projections 204, 206. The deflectable projections204, 206 can be configured to be deflectable between recessed andextended positions and to form a snap or interference fit with theapertures 200, 202, respectively.

In the illustrated embodiment, with reference to FIG. 10, thedeflectable projections 204, 206 can be formed integrally with sidewalls of the frame members 152, 154. In the illustrated embodiment, thedeflectable projections 204, 206 are formed as tabs in the side walls ofthe frame members 152A, 154A, with upper ends 208, 210 configured toform an interference fit with the apertures 200, 202, and in particular,the upper edges of the apertures 200, 202, as illustrated in FIG. 10.

Thus, as a solar module 170A is lowered onto a plurality of saddlemembers 102A, the frame members 152A, 154A can be lowered into the spacebetween the side walls 122A, 124A. Additionally, as the frame members152A, 154A are slid downwardly between the side walls and thedeflectable projections 204, 206 are aligned with the apertures 200,202, the deflectable projections will initially slide inwardly and thensnap outwardly, due to their bias, and interfere with the upper edges ofthe apertures 200, 202. As described above with reference to theembodiments of FIGS. 4-7, the apertures 200, 202 and the deflectableprojections 204, 206 can be configured to provide the desired holdingstrength or resistance to wind or other gravitational forces.

With reference to FIGS. 12-16, a further embodiment of the solar moduleretention assembly 100 is illustrated therein and identified generallyby the reference numeral 100B. The solar module retention assembly 100Bcan include a saddle member 102B which is most similar to the saddlemember 102. For example, the saddle member 102B includes projections160B, 162B. Optionally, the saddle member 102B can omit the side wall122 included in the saddle member 102. Optionally, each of theprojections 160B can include recesses 220, 222.

With reference to FIGS. 13-16, the projections 160B, 162B can beconfigured to form an interference fit with features on the framemembers 152B, 154B.

For example, with reference to FIG. 16, the frame members 152B, 154B caninclude apertures 150B with an interference tab 230. For example, theinterference tab 230 can be formed from a tab-shaped portion of thematerial forming a side wall of the frame members 152B, 154B, andextending, at its free end, into the aperture 150B. Thus, as theprojection, such as the projections 160B or 162B, are inserted into theaperture 150B, the interference tab 230 can engage one or more of therecesses 220, 222 so as to prevent the frame member 152B, 154B fromdisengaging from the projections 160B, 162B. Thus, the interference tab230 can provide a snap or interference fit between the saddle member102B and the frame members 152B, 154B.

FIGS. 13-15 illustrate an optional procedure for connecting the solarmodule 170B with the torque tube 16. For example, as shown in FIGS. 13and 14, the solar module 170B can be placed onto and supported by theflat surfaces at the distal ends 106B, 110B, and with the frame members152B, 154B spaced away from the projections 160B, 162B. Then, as shownin FIG. 15, the module 170B can be slid toward the right (as viewed inFIG. 15), until the projections 160B, 162B extend through the apertures150B and until the interference tabs 230 engage with the recesses 220 or222, thereby locking the frame members 152B, 154B to the saddle members102B.

This configuration provides some optional additional benefits. Forexample, by sizing the saddle members 102, 102B with flat surfaces atthe distal ends 106, 106B, 110, 110B that are sufficiently large toallow the solar module to be placed and rested upon the saddle members102, 102B in a position in which the projections do not contact theframe members the solar module 170 can be placed in a location and fullysupported by the saddle members 102, 102B. Assemblers can leave thesolar module 170, 170B in this position and move around the solar module170, 170B while aligning the apertures with the projections. Then, theentire module 170, 170B can be slid in a single direction into a lockedengagement. This can help reduce the number of assemblers required toattach a single solar module 170, 170B to a torque tube 16, and therebylower labor costs associated with constructing a solar energy collectionsystem. Other configurations can also be used.

While at least one exemplary embodiment has been presented in theforegoing detailed description, it should be appreciated that a vastnumber of variations exist. It should also be appreciated that theexemplary embodiment or embodiments described herein are not intended tolimit the scope, applicability, or configuration of the claimed subjectmatter in any way. Rather, the foregoing detailed description willprovide those skilled in the art with a convenient road map forimplementing the described embodiment or embodiments. It should beunderstood that various changes can be made in the function andarrangement of elements without departing from the scope defined by theclaims, which includes known equivalents and foreseeable equivalents atthe time of filing this patent application.

What is claimed is:
 1. A solar energy collection system comprising: atleast first and second solar modules, each comprising: a solarcollection member including an upper surface configured to receivesunlight for conversion into electrical energy and a lower surfaceopposite the upper surface, and a support frame connected to the lowersurface of the solar collection member; a plurality of solar moduleretention members supporting the first and second solar modules; and atleast one tool-less connection connected to at least one of theplurality of solar module retention member and configured to engage acorresponding support frame of one of the first and second solarmodules.
 2. The solar energy collection system according to claim 1,wherein the at least one tool-less connection comprises a snap fastener.3. The solar energy collection system according to claim 1, wherein theat least one tool-less connection comprises first and second leaf springmembers including first and second projecting portions extending intofirst and second apertures disposed on the support frame of the firstsolar module.
 4. The solar energy collection system according to claim3, wherein the first and second projecting portions comprise first andsecond slanted ramp faces, respectively, extending away from each other.5. The solar energy collection system according to claim 3, wherein theat least one tool-less connection is configured to be releasable fromthe support frame of the first solar module without the need for anytools.
 6. The solar energy collection system according to claim 1,wherein at least one of the tool-less connections comprises: at least afirst projection disposed on the at least one solar module retentionmember and having an enlarged distal end; at least a first aperturedisposed on the support frame of the first solar module; and adeflectable tab fixed to the support frame of the first solar module andextending across a portion of the first aperture so as to be deflectedby the first projection as the enlarged head is moved into the firstaperture, then spring back to a fully extended position so as to preventthe enlarged head from being removed from the aperture.
 7. The solarenergy collection system according to claim 1, wherein the support frameof the first solar module comprises at least a first side portiondisposed on a first side of a longitudinal axis of the solar collectionmember and a second side portion disposed on a second side of thelongitudinal axis of the solar collection member opposite the firstside, wherein at least first and second of the plurality of solar moduleretention members are fixed to a support body at positions spaced fromeach other by a distance approximately equal to a distance between thefirst and second side portions.
 8. The solar energy collection systemaccording to claim 1, wherein the at least one tool-less connection isconfigured to withstand to withstand upward forces of about at least 200pounds.
 9. The solar energy collection system according to claim 1,wherein the at least one tool-less connection is configured to withstandto withstand upward forces of about at least 1500 pounds.
 10. A solarenergy mounting arrangement comprising: a solar collector assemblyincluding a support frame comprising a first side portion and a secondside portion; a support arrangement comprising first and second supportsurfaces arranged so as to stably support the solar collector assembly;a first solar module retention member fixed to the support arrangementat the first support surface, the first solar module retention membercomprising a first tool-less connector configured to engage with a firstengagement feature of the first side portion of the support frame; asecond solar module retention member fixed to the support arrangement atthe second support surface, the second support surface spaced apart fromthe first support surface by a distance approximately equal to adistance between the first and second side portions of the supportframe, the second solar module retention member comprising a secondtool-less connector configured to engage with a second engagementfeature of the second side portion of the support frame; and wherein thefirst and second solar module retention members are sized so as to allowthe solar collector assembly to be pivoted around the first engagementfeature through a range of pivotal motion of at least 2 degrees betweena first tilted position in which the first tool-less connector isengaged with the first engagement feature and the second tool-lessconnector is completely disengaged with the second engagement featureand a second position in which the first tool-less connector is engagedwith the first engagement feature and the second tool-less connector isengaged with the second engagement feature.
 11. The mounting arrangementaccording to claim 10, wherein each of the first and second engagementfeatures comprises first and second apertures, and wherein the first andsecond tool-less connectors each comprise first and second leaf springmembers including first and second projecting portions extending intothe first and second apertures of a corresponding one of the first andsecond side portion of the support frame.
 12. The mounting arrangementaccording to claim 10, wherein the first and second tool-less connectorseach are configured to be releasable from the first and second sideportions of the support frame without the need for any tools.
 13. Themounting arrangement according to claim 10, wherein the first and secondtool-less connectors are each configured to withstand to withstandupward forces of about at least 200 pounds.
 14. The mounting arrangementaccording to claim 10, wherein the first and second tool-less connectorsare each configured to withstand to withstand upward forces of about atleast 1500 pounds.
 15. A solar module retention apparatus comprising: afirst solar module retention member fixed to a support body at a firstlocation, the first solar module retention member including at least afirst tool-less fastener configured to engage a first engagement featureof a first side portion of a support frame of a solar collection module;a second solar module retention member fixed to the support body at asecond location spaced from the first location by a distanceapproximately equal to a distance between the first side portion and asecond side portion of a support frame of a solar collector module, thesecond solar module retention member including at least a secondtool-less fastener configured to engage with a second engagement featureof the second side portion of the support frame of the solar collectionmodule; wherein the first and second engagement features are configuredto allow a solar collection module to be pivoted around the firstengagement feature through a range of pivotal motion of at least 2degrees between a first tilted position in which the first tool-lessfastener is engaged with the first engagement feature and the secondtool-less fastener is completely disengaged with the second engagementfeature and a second position in which the first tool-less connector isengaged with the first engagement feature and the second tool-lessconnector is engaged with the second engagement feature.
 16. The solarmodule retention apparatus according to claim 15, wherein the firstengagement feature comprises a flat portion and the second engagementfeature comprises a second flat portion, the first and second flatportions arranged so as to stably support a solar collection module. 17.The solar module retention apparatus according to claim 15, wherein thesecond engagement feature comprises a first aperture in the second sideportion of the support frame, and wherein the second tool-less fastenercomprises at least a first leaf spring member including at least a firstprojecting portion extending into the first aperture of the second sideportion of the support frame.
 18. The solar module retention apparatusaccording to claim 17, wherein the first projecting portion comprises afirst slanted ramp face.
 19. The solar module retention apparatusaccording to claim 15, wherein the first and second tool-less fastenersare each configured to withstand to withstand upward forces of about atleast 200 pounds.
 20. The solar module retention apparatus according toclaim 15, wherein the first and second tool-less fasteners are eachconfigured to withstand to withstand upward forces of about at least1500 pounds.